Chipping is an unavoidable phenomenon in the slot grinding process of hard and brittle materials. However, it should be reduced for the improvement of surface integrity in the manufacture of optical and semiconductor components. Electrolytic In-process Dressing (ELID) technique for metal bonded superabrasive grinding wheel has been developed for mirror surface grinding of hard and brittle materials. Electrically dressed wheel surface has sharply exposed abrasives and results in lower grinding force, higher grinding efficiency in grinding. The paper deals with a newly developed method for slot grinding using ELID and was implemented to improve grooved surface quality and decreases chipping size on the edge of the groove. As a result, we accomplished chipping-free grooves and obtained the clear ground surfaces on glass and WC.

Automatic monitoring of cutting process is one of the most important technologies for increasing the stability and the reliability of unmanned manufacturing system. In this study, basic methods which use the acoustic emission (AE) signals and cutting forces were proposed to monitor flank wear (width of flank wear) quantiatively. First, in order to detect flank wear, it was investigated that the influence of cutting conditions, that is, cutting velocity, feed and depth of cut, on AE signals () and cutting forces. Furthermore, the relation between flank wear and the measured signals (, cutting force) was discussed.

This paper presents a HGA-based(hybrid genetic algorithm) optimal control strategy to control of the swing motion and the transfer of the overhead crane. The objective is to achieve the regulation of the fast swing motion or fast position control. The controller is based on the state feedback. The HGA-based optimal algorithm is applied to find optimal gains of the controller. Computer simulation and experiments were performed to demonstrate the effectiveness of the proposed control scheme.

A control method for a robot hand grasping a object in a partially unknown environment will be proposed, where a proximate sensor detecting the distance between the fingertip and object was used. Particularly, the finger joints were driven servo-pneumatically in this study. Based on the proximate sensor signal the finger motion controller could plan the grasping process divided in three phases ; fast aproach, slow transitional contact and contact force control. That is, the fingertip approached to the object with full speed, until the output signal of the proximate sensor began to change. Within the perating range of the proximate sensor, the finger joint was moved by a state-variable feedback position controller in order to obtain a smooth contact with the object. The contact force of fingertip was then controlled using the blocked-line pressure sensitivity of the flow control servovalve for finger joint control. In this way, the grasping impact could be reduced without reducing the object approaching speed. The performance of the proposed grasping method was experimentally compared with that of a open loop-controlled one.

This paper addresses a welding task sequencing for robot arc welding process planning. Although welding task sequencing is an essential step in the welding process planning, it has not been considered through a systematic approach, but it depends rather on empirical knowledge. Thus, an effective task sequencing for robot arc welding is required. Welding perations can be classified by the number of welding robots. Genetic algorithms are applied to tackle those welding task sequencing problems. A genetic algorithm for traveling salesman problem (TSP) is utilized to determine welding task sequencing for a MultiWeldline-SingleLayer problem. Further, welding task sequencing for multiWeldline-MultiLayer welding is investigated and appropriate genetic algorithms are introduced. A random key genetic algorithm is also proposed to solve multi-robot welding sequencing : MultiWeldline with multi robots. Finally, the genetic algorithm are implemented for the welding task sequencing of three dimensional weld plate assemblies. Robot welding operations conforming to the algorithms are simulated in graphic detail using a robot simulation software IGRIP.

A laser Doppler vibrometer based on the laser heterodyne interferometry is employed to measure the vibration velocity of vibrating objects. In this paper, we propose a real time analog signal processor of a laser Doppler vibrometer to reduce the degradation of Doppler signals mainly caused by environmental noises. In the proposed real time signal processor of an laser Doppler vibrometer, a pre-processor and a logical motion direction detector are designed to reduce the detection errors of the object motion direction. Also, a noise detection and rejection circuit is designed to reject the unfiltered noises.

One of the recent changes in machining technology is rapid application of micro- and high precision grinding processes. A fine groove generation is necessary for the fabrication of optic, electronic and semiconductor parts, and achieved by chemical or mechanical processes. Slot grinding is very efficient for the generation of micro ordered groove with hard and brittle materials. As slot grinding is continuous, the ground depth become gradually shallow because of wheel wear. The form accuracy become worse from the increase of ground slot width by the loading phenomena at wheel side, results on chipping damage of the workpiece. The experiments achieve to the enhancement of the form accuracy and chipping free of the brittle materials using V shaped cast iron bonded diamond wheels. In this study we focused on the investigation of the effect of the high pressure air jet on the grinding characteristics. As a results, we found that the high pressure air jet is very effective on the reductions of the wheel wear, enhancement of the form accuracy.

In the assembly system, a pallet plays an important role of transfer and storage. As products become various, many different pallets are also necessary. Since some of them are redundant, a design of pallet with high flexibility is important. This paper suggests design alternatives, in designing pallets with high flexibility. The purpose of this study is to rationalize assembly process of mid-small size products. Every pallet has suitability values depending on characteristic factors of a product, and this value is determined by using AHP (Analytic Hierarchy Process) technique. As the characteristic factors of a product are changed, the suitability value is also changed. Design alternatives can be found by tracing change of the suitability value, which are based on correlation between the characteristic factors of a product and a pallet element.

The peak recoil force in a pistol have an effect on the reliability of the frame and target shooting. The experimental system has been established for measurement of the peak recoil force, which consists of force and velocity sensors, high speed camera. For effective operation of the system, a software has also developed, and combined with the hardwares. Several pistols have been tested and compared quantitatively on the peak recoil force and impact energy. It is concluded that the established system can be utilzed for checking peak force, and data accumulation for new pistol design.

The design models of a new product in general are created using clay models or wooden mock-ups. The reverse engineering(RE) technology enables us to quickly create the CAD model of the new product by capturing the surface of the model using laser digitizers or coordinate measuring machines. Rapid prototyping (RP) is another technology that can reduce the product development time by fabricating the physical prototype of a part using a layered manufacturing technique. In reverse engineering process, however, the digitizer generates an enormous amount of point data, and it is time consuming and also inefficient to create surfaces out of these data. In addition, the surfacing operation takes a great deal of time and skill and becomes a bottleneck. In rapid prototyping, a faceted model called STL file has been the industry standard for providing the CAD input to RP machines. It approximates the CAD model of a part using many planar triangular patches and has drawbacks. A novel procedure that overcomes these problems and integrates RE with RP is proposed. Algorithms that drastically reduce the point clouds data have been developed. These methods will facilitate the use of reverse engineered geometric data for rapid prototyping, and thereby will contribute in reducing the product development time.

Since grinding is a more complicated process than any other machining process, it is hard for operators to setup a grinding machine properly and to find out correctly abnormal grinding states resulting in damages to products. Abnormalities would be caused by improper setup, improper dressing/grinding conditions which are likely to be occurred without skilled operators' attention. In this study, an AE monitoring unit is developed to help operators conduct with ease setup, and set properly dressing/grinding conditions. AErms(root-mean-square) signal being monitored, on-going process states during grinding and dressing is visualized for machine operators to judge whether the processes are in good condition. Evaluation tests are carried out on centerless grinding machines-both cylindrical and internal. The developed AE monitoring system is verified to be useful to check grinding/dressing states in process even in the centerless grinding of which process is most unknown among various grinding methods because of the complex structure.

In most conventional design optimization of dynamic system, design sensitivities are utilized. However, design sensitivities based optimization method has numbers of drawback. First, computing design sensitivities for dynamic system is mathematically difficult, and almost impossible for many complex problems as well. Second, local optimum is obtained. On the other hand, Genetic Algorithm is the search technique based on the performance of system, not on the design sensitivities. It is the search algorithm based on the mechanics of natural selection and natural genetics. GA search, differing from conventional search techniques, starts with an initial set of random solutions called a population. Each individual in the population is called a chromosome, representing a solution to the problem at hand. The chromosomes evolve through successive iterations, called generations. As the generation is repeated, the fitness values of chromosomes were maximized, and design parameters converge to the optimal. In this study, Genetic Algorithm is applied to the actual dynamic optimization problems, to determine the optimal design parameters of the dynamic system.

For linkage mechanisms driven by a cam, cam profile is the major design factor and is determined by the cam follower motion. If a cam mechanism has additional kinematic linkage besides cam and follower then the follower motion should be specified from the motion of end linkage member so that cam would be able to generate the desired end linkage motion. In this paper, a cam-linkage mechanism is constructed with the combinations of modular linkage elements including cam and follower and as a result, a planar cam-linkage mechanism design software with the cam profile optimization function is developed and presented.

This paper suggests a monitoring method for the pulsed laser spot welding of the thin metal sheets using a point IR(InfraRed) sensor. A new criterion was introduced and the experimental results guaranteed the efficiency. The ideal radiation feature was derived from the mathematical model and was simulated. The radiation feature is robust to withstand the change of measuring condition and can be used to detect the absorbed laser energy. In an experiment, the radiation feature was examined for the differect laser energy. The pulse width and the laser power was variated and the radiation feature was examined. In the other experiment, the relationship between the weld strength and radiation feature was examined. Artificial Neural Network(ANN) was employed to find out the relationship. The correlation coefficient between the real strength and the estimated strength is high as 0.94 and the mean square error is low as 0.64 kgf learned parts. Another group of the welds was used to appraise the learning efficiency. The correlation coefficient between the measured and the estimated weld strength is high as 0.91.

Virtual Manufacturing System(VMS) is a computer model that represents the precise and whole structure of manufacturing systems and simulates their physical and logical behavior in operation. In this paper, a real time simulation for the virtual factory is proposed to integrate a process planning with scheduling under distributed environments. In order to communicate the information under distributed environments, we use a server/client concept using socket program and internet.

This paper presents results of monitoring grinding processes with on-the-machine measurement of surface roughness by using nux ratios of scattered lights. A compact, on-the-machine surface roughness sensor. which consists of a diodelaser and several optic units. is developed. The control unit is also developed. The developed sensor together with the controller is applied for monitoring grinding processes of two different grinding machines. Experimental results show that the nux ratios and their standard deviations measured by the developed sensor over the entire ground surface are useful for monitoring grinding conditions. In particular, the sensor and the control unit are proved to be useful for monitoring grinding processes in order to detect abnormal grinding conditions and dressing time.

In this paper the technique to predict tool wear theoretically in shearing process is suggested. The tool wear in the process affects the tolerances of final pans, metal flows and costs of processes. In order to predict the tool wear the deformation of workpiece during the process is analyzed by using non-isothermal finite element program. The ductile fracture criterion and the element kill method are also used to estimate if and where a fracture will occur and to investigate the features of the sheared surface in shearing process. Results obtained from finite element simulation, such as nodal velocities and nodal forces, are transformed into sliding velocity and normal pressure on tool monitoring points respectively. The monitoring points are automatically generated and the wear rates on these points are accumulated during the process. It is assumed that the wear depth on the tool surface is linear function of the lot sizes based upon the known experimental results. The influence of clearance between die and punch upon tool wear is also discussed.

The objective of this study is to develop an analysis scheme in order to predict regrinding due to tool wear in shearing process. The analysis of material now and fracture in shearing process should precede the prediction of tool wear. Thus the developed FE-program to analyze shearing process is used. In order to predict tool wear, the wear model is reformulated as an incremental form and then the wear depth of tool is calculated at each deformation path. Because the regrinding of shearing tool is determined on the basis of allowable size of burr, the analysis of shearing process is iteratively performed using the worn profile of tool. To show the effectiveness of the scheme the simulation result is compared with experimental one.

In designing the tracking system of an optical disc drive, it is first necessary to eliminate the undesired influence of any visible mechanical vibrations. In this paper a geometrical method to analyze the frequency response of an elastically supported planar rigid body has been presented. Using the theory of screw, a geometrical expression of a compliant transfer function which describes the effects of the locations of an applied force and observation on the response has been derived. Applying the substructure synthesis method, a technique to stabilize the tracking mechanical system has been presented with a numerical example.

This paper presents a precise tracking control scheme for the proposed parallel robot using artificial neural network. This control scheme is composed of three feedback controllers and one feedforward controller. Conventional PD controller and artificial neural network are used as feedback and feedforward controller respectively. A backpropagation learning strategy is applied to the training of artificial neural network, and PD controller outputs are used as target outputs. The PD controllers are designed at the robot dynamics based on inter-relationship between active joints and moving platform. Feedback controllers insure the total stability of system, and feedforward controller generates the control signal for trajectory tracking. The precise tracking performance of proposed control scheme is proved by computer simulation.

The traditional robot manipulators are actuated by continuous range of motion actuators such as motors or hydraulic cylinders. However, there are many applications of mechanisms and robotic manipulators where only a finite number of locations need to be reached, and the robot’s trajectory is not important as long as it is bounded. Binary manipulator uses actuators which have only two stable states. As a result, binary manipulators have a finite number of states. The number of states of a binary manipulator grows exponentially with the number of actuators. This kind of robot manipulator has some advantage compared to a traditional one. Feedback control is not required, task repeatability can be very high, and finite state actuators are generally inexpensive. And this kind of robot manipulator has a fault tolerant mechanism because of kinematic redundancy. In this paper, we solve the inverse kinematic problem of a binary parallel robot manipulator using neural network and test the validity of this structure using some arbitrary points m the workspace of the robot manipulator. As a result, we can show that the neural network can find the nearest feasible points and corresponding binary states of the joints of the robot manipulator

Monitoring of the cutting force signals in cutting process has been well emphasized in machine tool communities. Although the cutting force can be directly measured by a tool dynamometer, this method is not always feasible because of high cost and limitations in setup. In this paper an indirect cutting force monitoring system is developed so that the cutting force in turning process is estimated based on a AC spindle drive model. This monitoring system considers the cutting force as a disturbance input to the spindle drive and estimates the cutting force based on the inverse dynamic model. The inverse dynamic model represents the dynamic relation between the cutting force, the motor torque and the motor power. The proposed monitoring system is realized on a CNC lathe and its estimation performance is evaluated experimentally.

As the interface bonding phenomenon between the matrix and the reinforcements has a large effect on the mechanical properties of MMCs, a sugestion of the strength analysis technique considering the residual stress and the interface bonding phenomenon is very important for the design of pans and the estimation of fatigue behavior. In this paper the three dimensional finite element anaysis is performed during the elasto-plastic deformation of the particulate reinforced metal matrix composites. It was analyzed with the volume fractions in view of microscale. Bonding strength. interface separation and matrix void growth between the matrix and the reinforcements will be predicted on deformation under tensile loading. An interface seperation is estimated by the fracture criterion which is a critical value of generalized plastic work per unit volume. The shape of the reinforcement is assumed to be a perfect sphere. And the type of the reinforcement distribution is assumed as FCC array. The thermal residual stress in MMCs is induced by the heat treatment. It is included at the simulation as an initial residual stress. The element birth and death method of the ANSYS program is used for the estimation of the interface bonding strength, void generation and propagation. It is assumed that the fracture in the matrix region begin to occur under the external loading when the plastic work per unit volume is equal to the critical value. The fracture strain will be defined. The experimental data of the extruded >/606l Al composites are compared with the theoretical results.

For the optimal design of plasma facing components of a fusion reactor, thorough understanding of thermal behavior of high heat. nux components are required. The purpose of this research is to investigate the characteristics of heat flow and thermal stress in divertors which are exposed to high heat load varing with time and space-Numerical simulations of heat now and thermal stress for three types of diverter are performed using finite volume method and finite element method. Respectly, commercial FLUENT code are used in the heat flow simulation, and maximum surface temperature, temperature distribution and cooling rate are calculated. Commercial ABQUS code are used for calculating temperature distribution. thermal stress, strain and displacement. Through this computer simulation. design data for cooling system and Structural provided.

In this paper, the frequency response characteristics of the velocity controlled EHS system obtained by linear simulation method, nonlinear simulation method, and experimentation are compared one another, in order to verify propriety of the linearization method in case of analysis of hydraulic systems. The Bode diagrams are obtained by transforming time domain data of experimental results and nonlinear simulated ones with Fourier transform. The results of nonlinear simulation are more similar to the frequency response of the real systems than those of linear simulation. It is found that nonlinearity of hydraulic systems is mainly occurred from servo valve, and nonlinearity is increased as displacement of servo valve spool increases.

Most autonomous mobile robots view only things in front of them, and as a result, they may collide with objects moving from the side or behind. To overcome this problem. an Active Omni-directional Range Sensor System has been built that can obtain an omni-directional range data through the use of a laser conic plane and a conic mirror. Also, mobile robot has to know its current location and heading angle by itself as accurately as possible to successfully navigate in real environments. To achieve this capability, we propose a self-localization algorithm of a mobile robot using an active omni-directional range sensor in an unknown environment. The proposed algorithm estimates the current position and head angle of a mobile robot by a registration of the range data obtained at two positions, current and previous. To show the effectiveness of the proposed algorithm, a series of simulations was conducted and the results show that the proposed algorithm is very efficient, and can be utilized for self-localization of a mobile robot in an unknown environment.

In the feed drive systems or the spindle systems of machine tools that consist of many mechanical components, a torsional vibration is often generated because of its elastic elements in torque transmission-Generally, the accuracy of motion control system is strongly influenced by the dynamic behavior of coupled transmission components Especially, a torsional vibration caused by the elasticity of mechanical elements might deteriorate the quick movement of system and lead to shorten the life time of the mechanical transmission elements. So, it is necessary to analyze the electromechanical system mathematically to optimize the dynamic characteristics of the feed m1d spindle system. In this paper, based on the DC motor model, a model of electro-drive system with motor has been developed and an optimal criterion for tuning the gain of speed controller is discussed. The frequency bandwidth of the system and the damping ratio in time domain are optimal design specifications for the gain adjustment speed controller. The gains of PI speed controller are then derived from the bandwidth and damping ratio, and those relationships have been classified.